How to Install a Direct-Fit Muffler Kit on a Honda Civic

Quick Answer

For a 1990-1991 Honda Civic 1.5L, the BRExhaust Direct-Fit Muffler Kit 108-0165 bolts on without welding, making installation a straightforward weekend job if you follow the right sequence.

Step-by-Step Installation for the 1990-1991 Civic 1.5L

1. Raise the car and support it securely: Jack up the rear of the Civic and place jack stands under the frame rails. Never rely on the jack alone. Spray the old muffler hangers and bolts with penetrating oil and let it soak for 10 minutes. Check that the car is stable before you slide underneath.
2. Remove the old muffler: Unbolt the muffler from the intermediate pipe and pull the hanger bushings off the rubber mounts. If the bolts are seized, use a breaker bar or heat the nut with a torch—but keep a fire extinguisher nearby. Do not cut the pipe unless absolutely necessary. If you must cut, use a hacksaw or reciprocating saw, not a torch, to avoid damaging nearby fuel or brake lines.
3. Clean the mating flange: Use a wire brush to remove rust and old gasket material from the flange on the intermediate pipe. A clean surface ensures a tight seal and prevents exhaust leaks that cause ticking noises. Inspect the flange for cracks or warping; if it's damaged, replace the intermediate pipe before installing the new muffler.
4. Install the new muffler: Slide the new muffler's inlet over the intermediate pipe, aligning the hangers with the rubber mounts. Use the supplied hardware and tighten the clamp or bolts just snug—don't fully tighten yet. Ensure the muffler is oriented correctly: the outlet should point toward the rear, and the hangers should line up without forcing.
5. Attach the hangers and align the exhaust: Push the hanger bushings onto the rubber mounts. Check that the muffler sits level and doesn't touch the bumper, frame, or rear suspension. Adjust the angle by rotating the pipe slightly before final tightening. Leave a finger's width of clearance around the muffler to prevent rattles.
6. Tighten everything and test for leaks: Tighten all clamps and bolts to the manufacturer's torque spec (if known) or until snug. Start the engine and listen for hissing or popping sounds. Feel around the joints for exhaust pulses—if you detect a leak, re-tighten the clamp or add exhaust sealant. After a short drive, re-check the clamps and hangers; heat can loosen them.

Product Spotlight

• BRExhaust 1990-1991 Honda Civic 1.5L Direct-Fit Exhaust Muffler Kit 108-0165: The BRExhaust Direct-Fit Muffler Kit 108-0165 is crafted from high-grade aluminized steel and is engineered to meet or exceed original specifications. Aluminized steel resists corrosion better than plain steel, so the kit should last longer in wet or salty climates, and the direct-fit design means it bolts on without modification.